Caterpillar Cat 325C EXCAVATOR (Prefix DTF) Service Repair Manual Instant Download

Service Repair Manual Models 325C EXCAVATOR

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 1/6 Shutdown SIS Previous Screen Product: EXCAVATOR Model: 325C EXCAVATOR DTF Configuration: 325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine Disassembly and Assembly 325C Excavator 3126B Engine Supplement Media Number -RENR5368-03 Publication Date -01/04/2007 Date Updated -19/04/2007 i01924946 Alternator - Remove and Install - Engine in Chassis SMCS - 1405-010 Removal Procedure Note: Put identification marks on all wires for installation purposes. 1. Disconnect the positive battery terminal. This will prevent any damage to the wiring or the alternator. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 2/6 Illustration 1 g01003392 The above Illustration is a reference for the following steps. Illustration 2 g01003456 2. Remove bolt (7) . 3. Remove nut (6) from lower bolt (1) on alternator (3). Do not remove bolt (1) at this time. 4. Remove guard (5) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

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325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 3/6 5. Remove spacer (4) and bolt (2) . Illustration 3 g01003460 6. Remove belt (8) from the alternator. Illustration 4 g01003492 7. Disconnect cable assemblies (9) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 4/6 Illustration 5 g01001819 8. Remove rubber boot (10) . 9. Remove lower bolt (1) and alternator (3) . Installation Procedure Illustration 6 g01003392 The above Illustration is a reference for the following steps. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 5/6 Illustration 7 g01001819 1. Position alternator (3) and install lower bolt (1) . 2. Install boot (10) . Illustration 8 g01003492 3. Connect cable assemblies (9) to the original locations that were noted during the removal procedure. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 6/6 Illustration 9 g01003460 4. Install belt (8) on the alternator. Illustration 10 g01003456 5. Install bolt (2) and spacer (4). Refer to Illustration 6. 6. Position guard (5) . 7. Install bolts (7) . 8. Install nut (6) on lower bolt (1) on alternator (3). Refer to Illustration 6. 9. Connect the positive battery terminal. Copyright 1993 - 2020 Caterpillar Inc. Sat Jul 11 13:43:43 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 1/4 Shutdown SIS Previous Screen Product: EXCAVATOR Model: 325C EXCAVATOR DTF Configuration: 325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine Disassembly and Assembly 325C Excavator 3126B Engine Supplement Media Number -RENR5368-03 Publication Date -01/04/2007 Date Updated -19/04/2007 i01925121 Electric Starting Motor - Remove and Install - Engine in Chassis SMCS - 1453-010 Removal Procedure 1. Move the battery disconnect switch to the OFF position. 2. Disconnect the battery cable on the positive terminal of the battery. Move the battery cable away from the terminal. 3. Put identification marks on all harness assemblies and on all wires for installation purposes. Illustration 1 g00787887 4. Remove nut (1). Remove ground strap (2) from the electric starting motor. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 2/4 Illustration 2 g00787897 5. Raise the rubber boot and remove nut (3). Remove cable assemblies (4) from the electric starting motor. Illustration 3 g00787949 6. Remove the small nut and cover (5). Remove wires (6) . 7. Remove bolt (7). Move bracket (8) to the side. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 3/4 Illustration 4 g00886798 Typical example 8. Fasten a suitable lifting device to electric starting motor (10). The weight of the electric starting motor is approximately 29 kg (65 lb). 9. Remove bolts (9). Remove electric starting motor (10) from the flywheel housing. Installation Procedure Illustration 5 g00886798 1. Fasten a suitable lifting device to electric starting motor (10). The weight of the electric starting motor is approximately 29 kg (65 lb). 2. Place electric starting motor (10) in the flywheel housing. Install bolts (9) . Illustration 6 g00787949 3. Install bracket (8) in position. Secure bracket (8) with bolt (7) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 4/4 4. Install wires (6). Install cover (5). Secure cover (5) with small nut. Illustration 7 g00787897 5. Install cable assemblies (4). Secure wires (4) with nut (3). Install the rubber boot on nut (3) . Illustration 8 g00787887 6. Install ground strap (2). Secure ground strap (2) with nut (1) . 7. Connect the battery terminals. 8. Move the battery disconnect switch to the ON position. Copyright 1993 - 2020 Caterpillar Inc. Sat Jul 11 13:44:39 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 1/4 Shutdown SIS Previous Screen Product: EXCAVATOR Model: 325C EXCAVATOR DTF Configuration: 325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine Disassembly and Assembly 325C Excavator 3126B Engine Supplement Media Number -RENR5368-03 Publication Date -01/04/2007 Date Updated -19/04/2007 i01884773 Fuel Filter (Primary) and Fuel Filter Base - Remove and Install SMCS - 1261-010; 1262-010 Removal Procedure Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 2/4 Note: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system. Illustration 1 g00976401 1. Disconnect hose assemblies (1) . Illustration 2 g00976403 2. Disconnect hoses (4) . 3. Remove bolts (3) and remove fuel filter and base (2) . Installation Procedure Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 3/4 when changing fuel filters or water separator elements. Clean up fuel spills immediately. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Illustration 3 g00976403 1. Position fuel filter and base (2) . 2. Install bolts (3) . 3. Connect hoses (4) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 4/4 Illustration 4 g00976401 4. Connect hose assemblies (1) . Copyright 1993 - 2020 Caterpillar Inc. Sat Jul 11 13:45:34 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 1/6 Shutdown SIS Previous Screen Product: EXCAVATOR Model: 325C EXCAVATOR DTF Configuration: 325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine Disassembly and Assembly 325C Excavator 3126B Engine Supplement Media Number -RENR5368-03 Publication Date -01/04/2007 Date Updated -19/04/2007 i01925166 Water Separator - Remove and Install SMCS - 1263 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 2P-8250 Strap Wrench As 1 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 2/6 Illustration 1 g01001895 1. Open left side access doors (1) . Illustration 2 g00860593 2. Place a suitable container under drain hose (3) of the water separator. 3. Turn drain valve (2) counterclockwise in order to open. Drain the contents of the water separator. 4. Close the drain valve. 5. Loosen the hose clamp and disconnect drain hose (3) from the water separator. 6. Disconnect harness assembly (4) on the bottom of the water separator. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 3/6 Illustration 3 g00860611 7. Use Tooling (A) to remove fuel filter/water separator (6) from water separator base (5) . Illustration 4 g00794460 8. Remove bowl (8) and seal (7) from fuel filter/water separator (6) . Note: The filter is the top portion of the water separator. 9. Discard the used fuel filter/water separator. 10. Clean the inside surfaces of water separator base (5) and bowl (8) . Installation Procedure NOTICE https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 4/6 Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Note: Check the seal for wear or for damage. Replace the seal, if necessary. Illustration 5 g00794460 1. Install seal (7). Install bowl (8) onto a new fuel filter/water separator (6). Securely tighten bowl (8) . Note: The filter is the top portion of the fuel filter/water separator. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 5/6 Illustration 6 g00860611 2. Hand tighten fuel filter/water separator (6) until the fuel filter/water separator contacts water separator base (5). Turn the fuel filter/water separator for an additional 3/4 turn. Illustration 7 g00860593 3. Connect harness assembly (4) . 4. Turn drain valve (2) clockwise in order to close. 5. Install drain hose (3). Secure the drain hose with the hose clamp. 6. Prime the fuel system. Refer to Operation and Maintenance Manual, "Fuel System Priming Pump - Operate". 7. Start the engine. Check for leaks. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 6/6 Illustration 8 g01001895 8. Close left side access doors (1) . Copyright 1993 - 2020 Caterpillar Inc. Sat Jul 11 13:46:30 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 1/4 Shutdown SIS Previous Screen Product: EXCAVATOR Model: 325C EXCAVATOR DTF Configuration: 325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine Disassembly and Assembly 325C Excavator 3126B Engine Supplement Media Number -RENR5368-03 Publication Date -01/04/2007 Date Updated -19/04/2007 i01925251 Engine Oil Filter and Oil Filter Base - Remove - Engine in Chassis SMCS - 1306-011; 1308-011 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 2P-8250 Strap Wrench As 1 Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism. The precision components of the pump or of the motor can be damaged by contaminants or by dirt. All disassembly and assembly procedures must be performed on a clean work surface. Clean all the interior components in clean solvent. Dry all the interior components with compressed air. Plug ports and plug hoses on the machine during repair. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 2/4 Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. 1. Open the access door on the right side of the machine. Illustration 1 g00859179 2. Use Tooling (A) to remove engine oil filter (1) . Illustration 2 g00859184 3. Remove bolts (3) . 4. Remove oil filter base (2) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

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325C Material Handler DTF00001-UP (MACHINE) POWERED BY 3126 Engine(SE... 3/4 Illustration 3 g00863930 5. Remove O-ring seals (4) . Illustration 4 g00863940 Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 6. Remove plug (7) and the O-ring seal. Remove spring (6). Remove bypass valve (5) . Copyright 1993 - 2020 Caterpillar Inc. Sat Jul 11 13:47:26 UTC+0800 2020 All Rights Reserved. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/11

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